Pressurizing housing for a soft robotic actuator

ABSTRACT

Exemplary embodiments relate to pressurizable housings for a soft robotic actuator. The pressurized housings may be divided into an upper chamber in fluid communication with an internal void of the actuator, and a lower chamber connected to an inlet and an outlet. The upper chamber and lower chamber may be separated by a piston. By supplying a fluid to the lower chamber via the inlet, the piston is moved into the space previously occupied by the upper chamber, which reduces the volume of the upper chamber and increases the pressure in the internal void. This action allows the actuator to be rapidly inflated, and further simplifies the pressurization system and reduces its weight.

RELATED APPLICATIONS

This application is a Continuation application of U.S. Ser. No.16/208,669, filed Dec. 4, 2018, which claims priority to U.S.Provisional Patent Application Ser. No. 62/594,058, filed on Dec. 4,2017. The contents of the aforementioned application are incorporatedherein by reference.

FIELD OF THE DISCLOSURE

The disclosure relates generally to the field of robotics andparticularly to novel structures for pressurizing or depressurizing asoft robotic actuator.

BACKGROUND

Soft robotic actuators have generally been pressurized by supplying aninflation fluid to the internal reservoir of the actuator via a supplyline. The inflation fluid may be delivered under action of apressurizing device, such as a compressor or pump.

While effective, this configuration may have difficulty in supplying ahigh pressure in a short amount of time (due to limits on the amount ofinflation fluid that can be supplied by the pressurizing device). Thisis particularly true when multiple actuators are inflated together, asmight be the case with a gripper made up of several actuators. Thus, itmay be difficult to cause a soft actuator to curl in a relatively fastor forceful manner.

Furthermore, conventional inflation mechanisms may to be relativelycomplex and costly. An operator of a robotic system may plan to use thesystem as part of a large automation line requiring many actuators,perhaps at several points along the production line. Still further, whenretrofitting new actuators into an existing line, it may be difficult tofit a conventional model (including necessary mechanisms for inflation)into a small available space. Yet further, existing actuator assembliesmay be more complex than necessary if the operator's needs arerelatively simple.

Moreover, compressors and pumps tend to be heavy and relatively large,increasing the cost, weight, and size of the overall robotic system whendeployed as part of, or in close proximity to, the gripper.

SUMMARY

According to one aspect of an embodiment of the present invention, arobotic end effector may include a soft robotic actuator. The softrobotic actuator may include an elastomeric outer surface surrounding aninternal void. The soft robotic actuator may be configured to curl whenan inflation fluid is supplied to the internal void.

The end effector may further include a pressurizable housing dividedinto a first space and a second space, the first space being in fluidcommunication with the internal void. A fixed amount of inflation fluidmay be present in the first space, and a volume of the second space ismanipulable to change a volume of the first space and thereby alter aninternal pressure of the internal void. The pressurizable housing may beconnected to a single actuator, or a group of actuators.

In some embodiments, the first space and second space may be divided bya piston. A set of upper stops above the piston may define a maximumextension of the piston and may be used to define a maximum inflationpressure of the actuator. A set of lower stops below the piston maydefine a minimum extension of the piston and may be used to define amaximum degree of reverse curl achievable by the actuator. The upperand/or lower stops may be fixed or adjustable.

The end effector may also include an inlet port for supplying a secondspace fluid to the second space, and an outlet port for exhausting thesecond space fluid from the second space. For instance, the exhaust portmay be a valve. Alternatively, the exhaust port may be a pinholeopening, which may be provided in an orifice present in a disk capableof being inserted into the exhaust port. The second space fluid may behydraulic, pneumatic, etc.

The end effector may also include tubing connected to the inlet port forsupplying the fluid to the second space. The tubing may have a diameterof less than 10 mm, such as about 4 mm.

In some embodiments, a pressure sensor may be provided in the firstspace. The pressure sensor may detect an over- or under-pressure state,which may be indicative of a leak in the actuator, which may cause theactuator to fail.

In some embodiments, a method may include providing a robotic endeffector as described above, and supplying the second space fluid to theinlet port. In further embodiments, the second space fluid may beexhausted via the exhaust port.

In yet further embodiments, an indication may be received at acontroller, indicating that a pressure in the first space isunexpectedly low or unexpectedly high. In response to the indication,the controller may configured to perform at least one of the followingactions: transmitting a warning message to an operator of the endeffector; automatically stopping a machine to which the end effector isattached; stopping a manufacturing line including the machine to whichthe end effector is attached; or redirecting work from the machine towhich the end effector is attached to another machine present on thesame manufacturing line.

These and other embodiments are described in more detail below.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1A-1G depict various examples of soft robotic actuators.

FIG. 2 is a cutaway view of an exemplary structure for a pressurizedhousing.

FIGS. 3A-3C depict the state of the exemplary pressurized housing duringactuation and de-actuation.

FIGS. 4A-4C depict an alternative configuration for the hard stops ofthe exemplary pressurized housing.

FIG. 5 depicts an alternative structure for the housing including twosets of hard stops.

FIG. 6 is a flowchart describing an exemplary grasping technique inaccordance with exemplary embodiments.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The present invention will now be described more with reference to theaccompanying drawings, in which preferred embodiments of the inventionare shown. The invention, however, may be embodied in many differentforms and should not be construed as being limited to the embodimentsset forth herein. Rather, these embodiments are provided so that thisdisclosure will be thorough and complete, and will fully convey thescope of the invention to those skilled in the art. In the drawings,like numbers refer to like elements throughout.

Background on Soft Robotic Grippers

Conventional robotic actuators may be expensive and incapable ofoperating in certain environments where the uncertainty and variety inthe weight, size and shape of the object being handled has preventedautomated solutions from working in the past. The present applicationdescribes applications of novel soft robotic actuators that areadaptive, inexpensive, lightweight, customizable, and simple to use.

Soft robotic actuators may be formed of elastomeric materials, such asrubber, coated fabric, or thin walls of plastic arranged in an accordionstructure that is configured to unfold, stretch, twist, bend, extendand/or contract under pressure, or other suitable relatively softmaterials. As an alternative or in addition to accordion structures,other types or configurations of soft actuators employing elastomericmaterials may be utilized. They may be created, for example, by moldingor bonding one or more pieces of the elastomeric material into a desiredshape. Alternatively or in addition, different pieces of elastomericmaterial may be thermally bonded, or sewn. Soft robotic actuators mayinclude a hollow interior that can be filled with a fluid, such as air,water, or saline to pressurize, inflate, and/or actuate the actuator.Upon actuation, the shape or profile of the actuator changes. In thecase of an accordion-style actuator (described in more detail below),actuation may cause the actuator to curve or straighten into apredetermined target shape. One or more intermediate target shapesbetween a fully unactuated shape and a fully actuated shape may beachieved by partially inflating the actuator. Alternatively or inaddition, the actuator may be actuated using a vacuum to removeinflation fluid from the actuator and thereby change the degree to whichthe actuator bends, twists, and/or extends.

Actuation may also allow the actuator to exert a force on an object,such as an object being grasped or pushed. However, unlike traditionalhard robotic actuators, soft actuators maintain adaptive properties whenactuated such that the soft actuator can partially or fully conform tothe shape of the object being grasped. They can also deflect uponcollision with an object, which may be particularly relevant whenpicking an object off of a pile or out of a bin, since the actuator islikely to collide with neighboring objects in the pile that are not thegrasp target, or the sides of the bin. Furthermore, the amount of forceapplied can be spread out over a larger surface area in a controlledmanner because the material can easily deform. In this way, soft roboticactuators can grip objects without damaging them.

Still further, soft actuators are adaptive, and accordingly a singlefixture can grip multiple kinds of objects. Because the outer surfacesof soft actuators are relatively delicate, they can serve in roles suchas redirectors for easily bruised or damaged items (e.g., tomatoes)whereas hard fixtures might be limited to manipulating more robust items(e.g., brass valves).

Furthermore, soft actuators will typically not mark the surface beinggripped. Typically, when an easily-marked surface (e.g., a veneer) willbe gripped by a hard fixture, a protective coating or film may beapplied to prevent the part from being marked; this increases the costof manufacturing. With a soft actuator, this step may be omitted and thepart may be protected without a special coating or film.

Moreover, soft robotic actuators allow for types of motions orcombinations of motions (including bending, twisting, extending, andcontracting) that can be difficult to achieve with traditional hardrobotic actuators.

Conventional robotic grippers or actuators may be expensive andincapable of operating in certain environments where the uncertainty andvariety in the weight, size and shape of the object being handled hasprevented automated solutions from working in the past. The presentapplication describes applications of novel soft robotic actuators thatare adaptive, inexpensive, lightweight, customizable, and simple to use.

Soft robotic actuators may be formed of elastomeric materials, such asrubber, or thin walls of plastic arranged in an accordion structure thatis configured to unfold, stretch, and/or bend under pressure, or othersuitable relatively soft materials. They may be created, for example, bymolding one or more pieces of the elastomeric material into a desiredshape. Soft robotic actuators may include a hollow interior that can befilled with a fluid, such as air, water, or saline to pressurize,inflate, and/or actuate the actuator. Upon actuation, the shape orprofile of the actuator changes. In the case of an accordion-styleactuator (described in more detail below), actuation may cause theactuator to curve or straighten into a predetermined target shape. Oneor more intermediate target shapes between a fully unactuated shape anda fully actuated shape may be achieved by partially inflating theactuator. Alternatively or in addition, the actuator may be actuatedusing a vacuum to remove inflation fluid from the actuator and therebychange the degree to which the actuator bends, twists, and/or extends.

Actuation may also allow the actuator to exert a force on an object,such as an object being grasped or pushed. However, unlike traditionalhard robotic actuators, soft actuators maintain adaptive properties whenactuated such that the soft actuator can partially or fully conform tothe shape of the object being grasped. They can also deflect uponcollision with an object, which may be particularly relevant whenpicking an object off of a pile or out of a bin, since the actuator islikely to collide with neighboring objects in the pile that are not thegrasp target, or the sides of the bin. Furthermore, the amount of forceapplied can be spread out over a larger surface area in a controlledmanner because the material can easily deform. In this way, soft roboticactuators can grip objects without damaging them.

Still further, soft actuators are adaptive, and accordingly a singlefixture can grip multiple kinds of objects. Because the outer surfacesof soft actuators are relatively delicate, they can serve in roles suchas redirectors for easily bruised or damaged items (e.g., tomatoes)whereas hard fixtures might be limited to manipulating more robust items(e.g., brass valves).

Furthermore, soft actuators will typically not mark the surface beinggripped. Typically, when an easily-marked surface (e.g., a veneer) willbe gripped by a hard fixture, a protective coating or film may beapplied to prevent the part from being marked; this increases the costof manufacturing. With a soft actuator, this step may be omitted and thepart may be protected without a special coating or film.

Moreover, soft robotic actuators allow for types of motions orcombinations of motions (including bending, twisting, extending, andcontracting) that can be difficult to achieve with traditional hardrobotic actuators.

FIGS. 1A-1D depict exemplary soft robotic actuators. More specifically,FIG. 1A depicts a side view of a portion of a soft robotic actuator.FIG. 1B depicts the portion from FIG. 1A from the top. FIG. 1C depicts aside view of a portion of the soft robotic actuator including a pumpthat may be manipulated by a user. FIG. 1D depicts an alternativeembodiment for the portion depicted in FIG. 1C.

An actuator may be a soft robotic actuator 100, as depicted in FIG. 1A,which is inflatable with an inflation fluid such as air, water, saline,or any suitable liquid, gas, gel, foam, etc. The inflation fluid may beprovided via an inflation device 120 through a fluidic connection 118.

The actuator 100 may be in an uninflated state in which a limited amountof inflation fluid is present in the actuator 100 at substantially thesame pressure as the ambient environment. The actuator 100 may also bein a fully inflated state in which a predetermined amount of inflationfluid is present in the actuator 100 (the predetermined amountcorresponding to a predetermined maximum force to be applied by theactuator 100 or a predetermined maximum pressure applied by theinflation fluid on the actuator 100). The actuator 100 may also be in afull vacuum state, in which all fluid is removed from the actuator 100,or a partial vacuum state, in which some fluid is present in theactuator 100 but at a pressure that is less than the ambient pressure.Furthermore, the actuator 100 may be in a partially inflated state inwhich the actuator 100 contains less than the predetermined amount ofinflation fluid that is present in the fully inflated state, but morethan no (or very limited) inflation fluid.

In the inflated state, the actuator 100 may exhibit a tendency to curvearound a central axis as shown in FIG. 1A. For ease of discussion,several directions are defined herein. An axial direction passes throughthe central axis around which the actuator 100 curves, as shown in FIG.1B. A radial direction extends in a direction perpendicular to the axialdirection, in the direction of the radius of the partial circle formedby the inflated actuator 100. A circumferential direction extends alonga circumference of the inflated actuator 100.

In the inflated state, the actuator 100 may exert a force in the radialdirection along the inner circumferential edge of the actuator 100. Forexample, the inner side of the distal tip of the actuator 100 exerts aforce inward, toward the central axis, which may be leveraged to allowthe actuator 100 to grasp an object (potentially in conjunction with oneor more additional actuators 100). The soft robotic actuator 100 mayremain relatively conformal when inflated, due to the materials used andthe general construction of the actuator 100.

The actuator 100 may be made of one or more elastomeric materials thatallow for a relatively soft or conformal construction. Depending on theapplication, the elastomeric materials may be selected from a group offood-safe, biocompatible, or medically safe, FDA-approved materials. Theactuator 100 may be manufactured in a Good Manufacturing Process(“GMP”)-capable facility.

The actuator 100 may include a base 102 that is substantially flat(although various amendments or appendages may be added to the base 102in order to improve the actuator's gripping and/or bendingcapabilities). The base 102 may form a gripping surface that grasps atarget object.

The actuator 100 may include one or more accordion extensions 104. Theaccordion extensions 104 allow the actuator 100 to bend or flex wheninflated or deflated, and help to define the shape of the actuator 100when in an inflated or deflated state. The accordion extensions 104include a series of ridges 106 and troughs 108. The size of theaccordion extensions 104 and the placement of the ridges 106 and troughs108 can be varied to obtain different shapes or extension profiles.

Although the exemplary actuator of FIGS. 1A-1D is depicted in a “C” oroval shape when deployed, one of ordinary skill in the art willrecognize that the present invention is not so limited. By changing theshape of the body of the actuator 100, or the size, position, orconfiguration of the accordion extensions 104, different sizes, shapes,and configurations may be achieved. Moreover, varying the amount ofinflation fluid provided to the actuator 100 allows the actuator 100 totake on one or more intermediate sizes or shapes between the un-inflatedstate and the inflated state. Thus, an individual actuator 100 can bescalable in size and shape by varying inflation amount, and an actuatorcan be further scalable in size and shape by replacing one actuator 100with another actuator 100 having a different size, shape, orconfiguration.

The actuator 100 extends from a proximal end 112 to a distal end 110.The proximal end 112 connects to an interface 114. The interface 114allows the actuator 100 to be releasably coupled to other parts. Theinterface 114 may be made of a food- or medically-safe material, such aspolyethylene, polypropylene, polycarbonate, polyetheretherketone,acrylonitrile-butadiene-styrene (“ABS”), or acetal homopolymer. Theinterface 114 may be releasably coupled to one or both of the actuator100 and the flexible tubing 118. The interface 114 may have a port forconnecting to the actuator 100. Different interfaces 114 may havedifferent sizes, numbers, or configurations of actuator ports, in orderto accommodate larger or smaller actuators, different numbers ofactuators, or actuators in different configurations.

The actuator 100 may be inflated with an inflation fluid supplied froman inflation device 120 through a fluidic connection such as flexibletubing 118. The interface 114 may include or may be attached to a valve116 for allowing fluid to enter the actuator 100 but preventing thefluid from exiting the actuator (unless the valve is opened). Theflexible tubing 118 may also or alternatively attach to an inflatorvalve 124 at the inflation device 120 for regulating the supply ofinflation fluid at the location of the inflation device 120.

The flexible tubing 118 may also include an actuator connectioninterface 122 for releasably connecting to the interface 114 at one endand the inflation device 120 at the other end. By separating the twoparts of the actuator connection interface 122, different inflationdevices 120 may be connected to different interfaces 114 and/oractuators 100.

The inflation fluid may be, for example, air or saline. In the case ofair, the inflation device 120 may include a hand-operated bulb orbellows for supplying ambient air. In the case of saline, the inflationdevice 120 may include a syringe or other appropriate fluid deliverysystem. Alternatively or in addition, the inflation device 120 mayinclude a compressor or pump for supplying the inflation fluid.

The inflation device 120 may include a fluid supply 126 for supplying aninflation fluid. For example, the fluid supply 126 may be a reservoirfor storing compressed air, liquefied or compressed carbon dioxide,liquefied or compressed nitrogen or saline, or may be a vent forsupplying ambient air to the flexible tubing 118.

The inflation device 120 further includes a fluid delivery device 128,such as a pump or compressor, for supplying inflation fluid from thefluid supply 126 to the actuator 100 through the flexible tubing 118.The fluid delivery device 128 may be capable of supplying fluid to theactuator 100 or withdrawing the fluid from the actuator 100. The fluiddelivery device 128 may be powered by electricity. To supply theelectricity, the inflation device 120 may include a power supply 130,such as a battery or an interface to an electrical outlet.

The power supply 130 may also supply power to a control device 132. Thecontrol device 132 may allow a user to control the inflation ordeflation of the actuator, e.g. through one or more actuation buttons134 (or alternative devices, such as a switch, an interface, a touchdisplay, etc.). The control device 132 may include a controller 136 forsending a control signal to the fluid delivery device 128 to cause thefluid delivery device 128 to supply inflation fluid to, or withdrawinflation fluid from, the actuator 100.

Soft robotic actuators may be useful in many instances where a hardactuator is undesirable. For example, and without limitation, a softactuator may pick up a packaging blank or preform and provide it to ablow molder, after which the blow molder may reshape the blank into thedesired form based on the mold. After being shaped, the molded part willtypically be quite hot and deformable. The molded part may be retrievedby the soft actuator without damaging or deforming the molded part. Theactuator may then hold the molded part while it is being washed,labeled, filled, and/or capped. Other soft actuators may hold liveanimals gently, such as for inoculation, analysis or surgery.

One problem in conventional blow molding operations is that the objectbeing grasped has a different shape before and after blow molding(transitioning form the packaging blank to the finally-formed product.Whereas a hard gripper may have difficulty adapting to the changingshape (thus perhaps requiring two different types of grippers for asingle blow molding operation, a soft actuator may be sufficientlyadaptable to grasp both object shapes using the same gripper.

Soft robotic actuators may be inflated with a predetermined amount ofinflation fluid (or to a predetermined pressure), and the inflow/outflowof the actuators and/or the internal pressure of the actuator may bemeasured. Upon making contact with an object, the actuator may bedeflected and, as a result, inflation fluid may flow out of (or into)the actuator. This flow of inflation fluid may serve as a detector thatindicates the presence of an object at a position or generally incontact with the actuator. Alternatively, the actuator may include touchsensors, bending sensors, or other types of detection devices forregistering contact with an object.

FIG. 1E depicts a soft robotic actuator 100 with multiple fingers, inwhich the gripper hub 202 is attached to a robot arm RA, in which thefluid supply for actuation is provided via an external fluid line 118.The fingers 100 are shown in a reverse curled position and curled in thedirection 604.

FIGS. 1F and 1G depict a soft robotic actuator finger 100 that may beused with any embodiment discussed herein. Each finger 100 or actuator100 includes an elastomeric outer surface 3005 surrounding an internalvoid 3004, and the is configured to curl when an inflation fluid issupplied to the internal void 3004. A strain-limiting side 2003 resistsextension while the expanding side 3001 includes bellows features topromote extension as well as contraction upon a change in fluidpressure, either extension or contraction causing curling in onedirection or another. Reinforcing ribs 3003 constrain expansion andcontraction to occur primarily along the curling direction, and alsoprovide some texture or ridges for grasping.

FIGS. 1A-1G depict a particular type of soft robotic actuator, sometimesreferred to as an accordion-type soft actuator. However, numerous othertypes of soft actuators exist, some of which are described in connectionwith particular embodiments below. Soft actuators include actuatorsformed partially or entirely from soft or compliant materials, and mayincorporate or surround more conventional hard actuator materials.

Soft actuators may move in a variety of ways. For example, softactuators may bend, as shown above, or may twist, as in the example ofthe soft tentacle actuator described in U.S. patent application Ser. No.14/480,106, entitled “Flexible Robotic Actuators” and filed on Sep. 8,2014. In another example, soft actuators may be linear actuators, asdescribed in U.S. patent application Ser. No. 14/801,961, entitled “SoftActuators and Soft Actuating Devices” and filed on Jul. 17, 2015. Stillfurther, soft actuators may be formed of sheet materials, as in U.S.patent application Ser. No. 14/329,506, entitled “Flexible RoboticActuators” and filed on Jul. 11, 2014. In yet another example, softactuators may be made up of composites with embedded fiber structures toform complex shapes, as in U.S. patent application Ser. No. 14/467,758,entitled “Apparatus, System, and Method for Providing Fabric ElastomerComposites as Pneumatic Actuators” and filed on Aug. 25, 2014.

One of ordinary skill in the art will recognize that otherconfigurations and designs of soft actuators are also possible and maybe employed with exemplary embodiments described herein.

End Effectors

An end effector may be the device at the end of a robotic arm, designedto interact with the environment, and/or may be the last link (orendpoint) of the robot. At an endpoint, tools may be attached; or, theend effector may itself act as a tool. An end effector may include oneor both of a gripper or a tool. While grippers tend to hold, lift,transport and/or manipulate objects, tool functions often have acontrasting function, and may change a characteristic of the work objectrather than gripping or holding it. Tool functions may include weldingor fusing, spraying, dispensing, milling, screw or nut driving,flattening, cutting, and combinations of these.

At least four categories of end effector include impactive (e.g., jaws,claws, grasping a work object by direct impact, including holdingfriction); ingressive (e.g., penetrating the work object with needles,pins, or hackles); astrictive (e.g., essentially attractive or fieldforces such as Bernouilli lift, suction force, vacuum force, magnetic,electrostatic, van der Waals', ultrasonic standing waves, lasertweezing), and contigutive (e.g., essentially adhesive forces viacapillary action, glue, surface tension, freezing, chemical reaction).

In hard robotics, gripping may performed by using a form-followingstatic shape in the gripping surface (e.g., a concave cup to lift around object), or by friction force increased by closing hard fingers,jaws or claws. A soft robotic end effector may include gripperfunctionality, and may also or alternatively include some toolfunctionality. Soft robotic grippers may be impactive, and mayadditionally be made ingressive, astrictive, and/or contigutive via aparticular gripper/actuation morphology or configuration, or by addingan accessory tool within or along or opposite the soft robotic gripper.

A soft robotic gripper may include one or more soft robotic members,which may take organic prehensile roles of finger, arm, tail, or trunk,depending on the length and actuation approach. In the case of inflatingand/or deflating soft robotic members, two or more members may extendfrom a hub, and the hub may include a manifold for distributing fluid(gas or liquid) to the gripper members and/or a plenum for stabilizingfluid pressure to the manifold and/or gripper members. The members maybe arranged like a hand, such that the soft robotic members act, whencurled, as digits facing, a “palm” against which objects are held by thedigits; and/or the members may also be arranged like an cephalopod, suchthat the soft robotic members act as arms surrounding an additionalcentral hub actuator (suction, gripping, or the like). Generally,although not exclusively, as used herein, the terms “base plate”, “palmplate”, “bumper plate”, or “hub plate” may refer to a reference surfaceadjacent two or more soft robotic members against which the soft roboticmember may hold a work object, e.g., when curled in a “closing”direction, and from which the grip of the soft robotic members on thework object may be released, e.g., when the soft robotic members arecurled or recurled in an “opening” direction. The use of “plate” doesnot suggest that the member is fully planar—“plates”, unless otherwisedescribed, may have surface relief, contour, curves, peaks and valleys,texture, or the like—a “plate”, unless otherwise described, describes amember fitting within a plate-like envelope or aspect ratio.

Soft robotic gripper members may be formed of elastomeric materials,such as rubber, and/or thin walls of plastic arranged in an accordionstructure that is configured to unfold, stretch, and/or bend underpressure, or other suitable relatively soft materials. Soft roboticgripper members may include a channel and/or hollow interior that can befilled with a fluid, such as air, water, or saline to pressurize,inflate, and/or actuate the gripper member. Upon actuation, the shape orprofile of the gripper member changes by, e.g., variably curving,curling, including in opposing directions, or straightening.Alternatively or in addition, the gripper member may be actuated using avacuum to remove inflation fluid from the gripper member and therebychange the degree to which the gripper member bends, twists, and/orextends.

Actuation may also allow the gripper member(s) to exert a force on aworkpiece, such as a workpiece being grasped or pushed, as well aspartially or fully conforming to the shape of the workpiece beinggrasped. Soft robotic gripper members can also harmlessly deflect uponcollision with workpieces or the work environment.

Exemplary Pressurized Housings

As noted above, existing actuator pressurization systems may berelatively heavy, complex, and may not be capable of supplying inflationfluid quickly or to a relatively high pressure. Exemplary embodimentsprovide a comparatively low-cost, light-weight, and simplified controlmechanism that is capable of relatively fast and forceful actuation. Oneexample of such a system is depicted in FIG. 2.

In one embodiment a soft actuator 100 is (or multiple soft actuators100, such as may be used in a gripper) are attached to a housing 202divided into two chambers 214, 216 that are separated by a spool and/orpiston 204. The piston 204 may be connected to a spring 206 that biasesthe piston 204 towards the proximal end of the actuator 100.

An upper chamber 214 is fluidically connected to the reservoir 3004inside the soft actuator 100 so that the upper chamber 214 and the softactuator reservoir 3004 form a communal first space filled with a fixedamount of inflation fluid (e.g., air, water, hydraulic fluid). The lowerchamber 216 defines a second space.

The lower chamber 216 may be provided with an inflation valve 210through which an inflation fluid may be supplied to the lower chamber216. Similarly, the lower chamber 216 may be provided with an exhaustvalve 212 that allows an inflation fluid to be exhausted from the lowerchamber 216. An amount of fluid present in the first space may beselected so that, when the exhaust valve 212 leading from the lowerchamber 216 is opened (and no fluid is being supplied because theinflation valve 210 is in a closed configuration), the pressure in thefirst space balances the spring force applied by the spring 206 and thespring 204 is pushed downward to a first predetermined position.

FIG. 3A depicts the pressurized housing 202 in such an initial state. Asshown, the actuator 100 is deflated and the piston 204 is in a loweredposition. The actuator 100 may be inflated by supplying an inflationfluid to the lower chamber 216, as shown in FIG. 3B. This may beaccomplished by opening the inflation valve 210 supplying the secondspace while closing the exhaust valve 212 from the second space. In thisway, the piston 204 can be made to move up to decrease the volume of thefirst space. Thus, less space is available in the upper chamber of thehousing 202 to accommodate the fixed amount of inflation fluid, whichincreases the pressure in the reservoir 3004 of the soft actuator 100.This causes the soft actuator 100 to inflate.

In order to deflate the soft actuator 100, the inflation fluid may beremoved from the lower chamber 216. This may be accomplished by openingthe exhaust valve 212 supplying the second space while closing the inletvalve 210 to the second space, as shown in FIG. 3C). As a result, thepressure in the second space returns to the ambient pressure of thesurrounding room (as the exhaust valve provides an air path between thesecond space and the local environment). The pressure in the first spacewill decrease to an amount commensurate with the action of the spool'sreturn spring 206 pulling the piston 204 to the bottom of the housing202. This action forces the spool 206 away from the actuator 100 andprovides an increased volume in the first space for the fixed amount ofinflation fluid in the first communal space. The balance point may bemanipulated by using a different spring 206 with a different springconstant to bias the piston 204 towards or away from the actuator 100.

It is noted that it is not necessary to employ a hard spool or piston todrive the inflation fluid. In some embodiments, the fluid in the upperchamber 214 (e.g., air) may be different from the fluid in the lowerchamber 216 (e.g., water) such that the two fluids do not mix. When thefluid in the lower chamber 216 pushes against the fluid in the upperchamber 214, the fluid in the upper chamber 214 may be driven into theactuator 100. In other embodiments, the piston or hard spool may bereplaced by a flexible medium, such as a diaphragm, or another devicefor parting the upper and lower portions.

The inlet valve 210 and/or exhaust valve 212 may be connected torelatively small and/or high pressure pneumatic or hydraulic lines. Theexhaust valve 212 may optionally be a vacuum port, and optionally may beconnected to a venturi generator. The use of a smaller tube may beadvantageous because smaller tubes typically have a smaller bend radiusthan larger tubes. Consequently, it is easier to snake a small tube intoa confined space. Furthermore, smaller tubes are less likely to kink upin applications where the gripper is mounted to a complex moving system,such as a robotic arm. Moreover, in applications where severalindependently addressable systems need to fit into a tight space,smaller tubes are more convenient to use than larger tubes. Stillfurther, in the case where the soft robotic gripper is mounted to arobotic arm, the robotic arm is often provided with relatively smalldiameter pneumatic lines. Although it would be advantageous to use theseexisting lines instead of running new lines to the gripper, the smalldiameter of the existing lines make this difficult or impossible, giventhe relatively large size of the tubes needed to feed a conventionalsoft robotic actuator (resulting in an excessively slow rate ofinflation of the actuator).

Relatively small tubes can be used in connection with the embodimentsdescribed herein because it takes a relatively small amount of force todrive the piston, given that the actuators typically need about 2-12 psiof fluid pressure for inflation. Even brief exposure to relatively highpressure air (e.g., at about 100 psi) in the second space 216 createssufficient pressurization in the housing 202 to move the piston 204, andthus only a small molar quantity of fluid is needed. Thus, small tubescan be used to deliver that relatively small molar quantity.

In one example, a conventional soft robotic actuator may utilize tubingdiameters in the range of 10-12 mm. With the exemplary embodimentsdescribed herein, a sufficient quantity of fluid could be delivered tothe second space using a tube diameter of less than 10 mm, preferably4-8 mm, and more preferably about 4 mm.

In further embodiments, the exhaust valve 212 may be replaced with anorifice, such as a pin hole opening, which further simplifies the designof the device. This opening may continuously leak air from the secondspace, thus allowing the actuator 100 to become slowly depressurizedover time as air leaks from the second space.

In some embodiments, the orifice may be present in a disk that fits intoan opening in the housing, such that one disk may be swapped foranother. Different disks may include differently sized orifices, thusallowing for the rate of leakage to be adjusted by replacing the disk.Furthermore, the orifice may be used to create a time delay for systemactivation. As a result, actuation of the system may be made moregentle, which may prevent damage to the actuator or a grasp target.

Furthermore, changing the rate of inflation (e.g. using the above-notedorifices) may reduce the magnitude of undamped oscillation experiencedby the actuator 100 during inflation. In other words, the actuators 100may swing less violently when moving to the inflated state. The same canbe said for a vacuum-driven reverse curl process if the rate ofexhaust/evacuation is slowed.

Undamped oscillation is undesirable for applications where the actuators100 are used in tight spaces and it is important for the actuators 100to avoid colliding with a container or neighboring objects. By slowingthe rate of inflation/evacuation, the grasp quality for suchapplications may be improved.

The inflation fluid present in the upper chamber may be the same as, ordifferent than, the inflation fluid supplied to the lower chamber.Either or both of the upper chamber and the lower chamber may behydraulically or pneumatically controlled. In some embodiments, eitheror both of the inflation fluids may be air.

As shown in FIGS. 2 and 3B, the movement of the spool and/or piston intothe upper chamber may be limited by one or more hard stops 208. The hardstops 208 may be positioned so as to limit the minimum volume of thefirst space in order to fix the maximum pressure inside the actuator100. By placing the hard stops at a relatively low position, the maximumpressure may be set relatively low, as shown in FIGS. 3A-3C. By placingthe hard stops at a relatively high position, the maximum pressure maybe set relatively high, as shown in FIGS. 4A-4C.

The hard stops 208 may also function as a safety feature that preventshigh pressure air/fluid from causing a catastrophic failure at a damagedactuator 100. Conventionally, when an actuator is damaged, high pressurefluid may be vented from the damaged portion, causing the actuator tocatastrophically fail (e.g., popping), thereby dropping or launching agripped object. In exemplary embodiments, the existence of the hardstops 208 means that the air used for bending the actuator is decoupledfrom the air used to activate and deactivate the system. Accordingly,the risk of over-pressurizing the actuator is reduced or eliminated.

Because the piston 204 may be driven (in the system's actuated state)against the hard stops 208 with house air, it may be difficult orimpossible to sufficiently relieve pressure on the actuator(s) 100 bydriving the piston 208 head backward. As a result, the actuators 100could be damaged. To address this potential issue, it may beadvantageous to include a pressure sensor in the actuator-facing section(e.g., the upper portion 214) of the housing 202 capable of detectingover-pressure situations. Over-pressure may be detected, e.g., based ondeflection and/or compression. Upon detecting an over-pressuresituation, a fault signal may be transmitted to a controller, whichshuts down (deactivates) the system, and/or provides a warning or a pushnotification to the operator or a system computer. In anotherembodiment, a warning signal may be transmitted upon detecting anover-pressure situation, informing an operator of the system that theactuator is being operated in a manner that may reduce its lifespan.

Still further, the pressure sensor could be used as part of aclosed-loop control system that shuts off the supply of high pressure tothe lower portion 216 of the housing 202 when the upper portion 214 ofthe housing has hit a desired set pressure. In this way, the closed-loopcontroller may achieve any desired inflation pressure for the actuator.Alternatively, the pressure sensor could be used with a closed loopcontroller to shut off the valve 212 that exhausts/or evacuates thelower housing when the upper portion 214 has achieved a desired level ofvacuum. In this way the system can achieve any desired amount of reversecurl.

Still further, if the sensor is reading a low pressure in the actuator100 (a pressure that is lower than the intended inflation pressure) thismay be an indication of a hole in the actuator 100 or a leak in thehousing 202.

A low or high measurement by the pressure sensor could result in avariety of events, such as: 1) a real-time warning message being sent tothe plant's manager to tell them there is a problem with theirmanufacturing line, 2) automatically stopping the machine the actuatoris a part of, 3) stopping the entire manufacturing line, 4) instructingthe manufacturing line to redirect work to a duplicate machine on theline that does not have a broken actuator, or 5) any of a number ofother programmed responses.

As shown in FIG. 5, a second set of hard stops 208-2 placed below thepiston 204 (i.e., in the lower chamber 214) may be used to define adegree of reverse curl of the actuator 100. As inflation fluid isremoved from the actuator 100, the actuator 100 may return to a restingor neutral state. If actuation fluid continues to be removed beyond theneutral state, the actuator 100 may be configured to curl in a directionopposite to the actuation direction (i.e., away from the graspingsurface of the actuator). In order to facilitate removal of theinflation fluid from the actuator (i.e., by increasing the volume in thefirst space by enlarging the upper chamber), a return spring 206 maydraw the piston 204 backwards, into the lower chamber 216. The optionalsecond hard stops 208-2 may establish a lower limit to which the spring206 can be drawn, thus defining a maximum volume available to the firstcommunal space defined by the upper chamber 214 and the actuatorreservoir 3004. Accordingly, the maximum amount of reverse curl may beregulated.

The first hard 208-1 stops and/or the second hard stops 208-2 may bestatic so as to define a maximum positive and a maximum negativepressure. Alternatively, either or both of the hard stops 208-1, 208-2may be adjustable so as to reconfigure the maximum amounts of forwardcurling or reverse curling for different applications.

The piston 204 may be any of a number of structures, such as a spool,disk, piston head, etc. In addition to or as an alternative to hydraulicor pneumatic control, the piston 204 may be moved by other means, suchas electric motor or mechanical linkage.

Although FIG. 2 depicts the pressurizing housing 202 attached to asingle actuator 100, a single housing 202 could also be used to controlmultiple actuators 100. This may be useful, for example, in order tocontrol a gripper made up of several actuators 100 that are intended tobe actuated together.

Although the above examples have been provided to describe the system,other configurations and variations are contemplated. For example, thesystem need not be driven by air. Instead, an electric motor or asolenoid may drive a piston rod.

In another example, hydraulic fluid may be used in the actuators, whichmay be forced into the actuators through action of air provided in thelower part of the housing, or vice versa. Likewise, the system could beprovided entirely with hydraulic fluids (e.g., liquid in the actuatorand the lower part of the housing 202), or may be entirely pneumatic. Inthe hydraulic case, a single port may be used as an inlet and an outlet.

Furthermore, the inlet port 210 or exhaust port 212 may includeinterchangeable orifices of different sizes, in order to easily changethe rate of inflation or deflation of the actuators. The exhaust portmay also be replaced with a small orifice that bleeds air at arelatively slow rate. When pressurized, the system is able to overcomethis slow bleed; when depressurized, fluid may leak from the orifice toremove pressure from the housing. As a result, no valve is necessary atthe exhaust port 212. This reduces the complexity and cost of thesystem, and also allows the inflation and/or deflation time of theactuator 100.

On the other hand, the exhaust port 212 may be replaced by a venturivacuum generator. When pressurized air is provided to the venturi, itpulls air from the housing 202, which allows the system to bedepressurized more quickly.

Advantageously, exemplary embodiments can rely upon a compressorprovided remotely from the finger to be inflated, such as a compressorprovided in the building housing the robotic system (potentially as partof a larger system involving many soft robotic actuators).

In one example, an exemplary embodiment may be supplied with air from acompressor provided in a mechanical room of the facility in which theactuator is deployed, without alteration of the air pressure beforearrival at the housing. Soft robotic systems typically only require arelatively small pressure change (e.g., in the range of 2-12 psi) toinflate an actuator. Conventionally, soft robotic systems either utilizespecial-purpose compressors capable of providing such a relatively lowamount, or connect to the facility's house system, which provides air ata much higher pressure (e.g., 100 psi). To accommodate the higherpressure, conventionally a regulator is used to step the house airpressure down to the grip air pressure.

In contrast, the system described herein decouples the fluid provided tothe internal void of the soft actuator from the fluid used to drive thepiston. Consequently, the regulator can be removed, further reducing thesize, cost, and complexity of the system.

In some embodiments, the valves may be provided on or near the housing,and electric lines may be run to the housing to control the valves. Inothers, the valves may be located remotely from the housing, with apneumatic or hydraulic line run from the valves to the housing.

Example Method

FIG. 6 describes a procedure for deploying and using an end effector asdescribed above. The actions described in FIG. 6 may be embodied asinstructions performed by a controller that controls an end effector.

At block 602, an end effector may be provided. The end effector mayinclude a pressurizable housing as described above.

At block 604, an inflation fluid may be supplied to the lower chamber.The inflation fluid may be supplied via the inlet port. A predefinedamount of inflation fluid may be supplied (e.g., via a compressor) inorder to achieve a desired amount of bend in the actuator. In someembodiments, the amount of inflation fluid supplied may be adynamically-determined amount computed by the controller based on adesired amount of bend for the actuator.

Alternatively, a vacuum may be applied at the lower chamber by removingfluid from the lower chamber. This allows the actuator to reverse-curl.The amount of fluid removed may be selected based on the desired amountof reverse-bend.

At block 606, the system may determine whether the application of theinflation fluid or vacuum has caused a pressure abnormality. Thepressure abnormality may be detected by a pressure sensor provided inthe upper chamber.

If a pressure abnormality is detected at block 606, then at block 608the controller may trigger an over- or under-pressure action, asappropriate. The action may include, for example, transmitting areal-time warning message to an operator of the robotic system,automatically stopping the machine the actuator is a part of, stoppingthe entire manufacturing line, instructing the manufacturing line toredirect work to a duplicate machine on the line that does not have abroken actuator, or any of a number of other programmed responses.

If a pressure abnormality is not detected at block 606, then at block610 the inflation fluid or vacuum may be exhausted to return thepressurizable housing to a neutral configuration. This process may berepeated by returning to block 604, so that the end effector may be usedto grasp another object.

The above-described method may be embodied as instructions or logicstored on a non-transitory computer-readable medium. When executed, theinstructions or logic may cause a processor circuit to perform theabove-described method using a robotic system.

General Notes on Terminology

Some embodiments may be described using the expression “one embodiment”or “an embodiment” along with their derivatives. These terms mean that aparticular feature, structure, or characteristic described in connectionwith the embodiment is included in at least one embodiment. Theappearances of the phrase “in one embodiment” in various places in thespecification are not necessarily all referring to the same embodiment.Moreover, unless otherwise noted the features described above arerecognized to be usable together in any combination. Thus, any featuresdiscussed separately may be employed in combination with each otherunless it is noted that the features are incompatible with each other.

With general reference to notations and nomenclature used herein, thedetailed descriptions herein may be presented in terms of programprocedures executed on a computer or network of computers. Theseprocedural descriptions and representations are used by those skilled inthe art to most effectively convey the substance of their work to othersskilled in the art.

A procedure is here, and generally, conceived to be a self-consistentsequence of operations leading to a desired result. These operations arethose requiring physical manipulations of physical quantities. Usually,though not necessarily, these quantities take the form of electrical,magnetic or optical signals capable of being stored, transferred,combined, compared, and otherwise manipulated. It proves convenient attimes, principally for reasons of common usage, to refer to thesesignals as bits, values, elements, symbols, characters, terms, numbers,or the like. It should be noted, however, that all of these and similarterms are to be associated with the appropriate physical quantities andare merely convenient labels applied to those quantities.

Further, the manipulations performed are often referred to in terms,such as adding or comparing, which are commonly associated with mentaloperations performed by a human operator. No such capability of a humanoperator is necessary, or desirable in most cases, in any of theoperations described herein, which form part of one or more embodiments.Rather, the operations are machine operations. Useful machines forperforming operations of various embodiments include general purposedigital computers or similar devices.

Some embodiments may be described using the expression “coupled” and“connected” along with their derivatives. These terms are notnecessarily intended as synonyms for each other. For example, someembodiments may be described using the terms “connected” and/or“coupled” to indicate that two or more elements are in direct physicalor electrical contact with each other. The term “coupled,” however, mayalso mean that two or more elements are not in direct contact with eachother, but yet still co-operate or interact with each other.

Various embodiments also relate to apparatus or systems for performingthese operations. This apparatus may be specially constructed for therequired purpose or it may comprise a general purpose computer asselectively activated or reconfigured by a computer program stored inthe computer. The procedures presented herein are not inherently relatedto a particular computer or other apparatus. Various general purposemachines may be used with programs written in accordance with theteachings herein, or it may prove convenient to construct morespecialized apparatus to perform the required method steps. The requiredstructure for a variety of these machines will appear from thedescription given.

In the foregoing description, it can be seen that various features aregrouped together in a single embodiment for the purpose of streamliningthe disclosure. This method of disclosure is not to be interpreted asreflecting an intention that the claimed embodiments require morefeatures than are expressly recited in each claim. Rather, as thefollowing claims reflect, inventive subject matter lies in less than allfeatures of a single disclosed embodiment. Thus the following claims arehereby incorporated into the Detailed Description, with each claimstanding on its own as a separate embodiment. In the appended claims,the terms “including” and “in which” are used as the plain-Englishequivalents of the respective terms “comprising” and “wherein,”respectively. Moreover, the terms “first,” “second,” “third,” and soforth, are used merely as labels, and are not intended to imposenumerical requirements on their objects.

What has been described above includes examples of the disclosedarchitecture. It is, of course, not possible to describe everyconceivable combination of components and/or methodologies, but one ofordinary skill in the art may recognize that many further combinationsand permutations are possible. Accordingly, the novel architecture isintended to embrace all such alterations, modifications and variationsthat fall within the spirit and scope of the appended claims.

Any or all of the above-described techniques may be implemented bysuitable hardware, including pneumatic, hydraulic, mechanical,electrical, magnetic, etc. hardware. Some embodiments may utilize logicstored on a non-transitory computer-readable medium. When executed byone or more processors, the logic may cause the processors to performthe techniques identified above. The logic may be implemented fully orpartially in hardware. The logic may be included as part of a controllerfor controlling the actuation, de-actuation, movement, position, etc. ofa soft robotic actuator and/or a soft robotic system employing one ormore actuators in a gripper arrangement.

As used herein, structures, acts, steps, and functions are given variousnames or labels. This paragraph describes terminology that is usedalternatively, in some cases interchangeably, and in some casesequivalently. Generally, one of skill in the art will recognize andunderstand identity, equivalency, and the similarities and differencesamong alternative terms of art and/or words having a plain technicalmeaning. As used herein, an end effector may include an effectorincluding a tool or one to which a tool may be mounted, including EOAT202 and the like. Bendable members may include soft robotic members suchas soft robotic actuators 100.

We claim:
 1. A robotic end effector comprising: a soft robotic actuatorcomprising an elastomeric outer surface surrounding an internal void,wherein the soft robotic actuator is configured to curl when aninflation fluid is supplied to the internal void; a pressurizablehousing divided into a first space and a second space, the first spacebeing in fluid communication with the internal void, wherein a fixedamount of inflation fluid is present in the first space; and a volume ofthe first space is manipulable to alter an internal pressure of theinternal void; and a piston dividing the first space from the secondspace, wherein the piston is movable to adjust a volume of the firstspace and the piston is driven by one or more of an electric motor or amechanical linkage.
 2. The end effector of claim 1, further comprising:an inlet port for supplying a second space fluid to the second space;tubing connected to the inlet port; and an outlet port for exhaustingthe second space fluid from the second space.
 3. The end effector ofclaim 2, wherein a diameter of the tubing is less than 10 mm;
 4. The endeffector of claim 1, wherein the diameter of the tubing is about 4 mm.5. The end effector of claim 1, wherein the exhaust port is a valve. 6.The end effector of claim 1, wherein the exhaust port comprises apinhole opening.
 7. The end effector of claim 6, wherein the pinholeopening is an orifice present in a disk capable of being inserted intothe exhaust port.
 8. The end effector of claim 1, wherein thepressurizable housing is connected to a plurality of soft roboticactuators.
 9. The end effector of claim 1, further comprising a set ofupper stops between the piston and the actuator in the first space. 10.The end effector of claim 9, wherein the upper stops are adjustable. 11.The end effector of claim 1, further comprising a set of lower stops inthe second space.
 12. The end effector of claim 11, wherein the lowerstops are adjustable.
 13. The end effector of claim 1, furthercomprising a pressure sensor present in the first space.
 14. The endeffector of claim 1, wherein the second space fluid is a pneumaticfluid.
 15. The end effector of claim 1, wherein the second space fluidis a hydraulic fluid.
 16. A method comprising: providing a robotic endeffector according to claim 1; and supplying the second space fluid toan inlet port in fluid communication with the second space.
 17. Themethod of claim 16, further comprising exhausting a second space fluidpresent in the second space via an exhaust port.
 18. The method of claim16, further comprising receiving an indication at a controller that apressure in the first space is unexpectedly low or unexpectedly high.19. The method of claim 18, wherein, in response to the indication, thecontroller is configured to transmit a warning message to an operator ofthe end effector;
 20. The method of claim 18, wherein, in response tothe indication, the controller is configured to perform at least one ofthe following actions: automatically stopping a machine to which the endeffector is attached; stopping a manufacturing line including themachine to which the end effector is attached; or redirecting work fromthe machine to which the end effector is attached to another machinepresent on the same manufacturing line.